JPS62109621A - Manufacturing process for breathable composite material - Google Patents

Abstract

PURPOSE:To manufacture the breathable composite material in one process quickly and in mass production by inserting the heated needle into the laminating material consisting of plastic film and non-woven cloth, and perforating and welding simultaneously. CONSTITUTION:The composite Sa is formed up by putting together plastic film 1 made of polypropylene and plastic non-woven cloth 2, and passed through between the revolution rollers A and B, with the face of non-woven cloth 2 being contacted to the roller B. At that time, the tip of heated needle K heated up over the dissolution temperature (250 deg.C) of polypropylene film 1 is inserted into the composite Sa from the film side and pierced the non-woven cloth 2. By the said process, the film section and the non-woven cloth section around the film are dissolved, and welded each other to join up the composite Sa, and also the heated needle K is drawn out of the revolving roller A, leaving the micro pore 3. Thus, the breathable composite material S having numerous welding portions and strong joining power is produced.

Description

Detailed Description of the Invention (Industrial Field of Application) The present invention relates to a method for producing composite materials such as breathable plastic composite films, packaging materials for foods, desiccants, etc.
It is used for a variety of purposes, such as a skin packaging material for glass wool insulation, a cover for outdoor vegetables, or an interior material for heat retention to prevent condensation and mold.Technology to manufacture the composite by bonding it at the same time as creating micro-holes. Belongs to a field.

(Conventional problems) Composite films containing conventional plastic films,
Dry lamination using adhesive.

There are methods such as a method in which molten polyethylene resin is poured onto the film surface or between the films and hardened and bonded, and a thermal lamination method in which films coated with a heat sealing agent are stacked on the film surface and bonded under heat and pressure. However, in addition to the overlapping process, both methods require processing for adhesion, such as applying an adhesive or heat sealant or pouring molten resin, which is a time-consuming and troublesome process that requires advanced technology. Ta. In order to ensure breathability, perforations are performed after the composite film is formed. In other words, even if a composite is made by stacking a plurality of perforated plastic films to ensure breathability, fabrics that themselves have breathability, or non-woven fabrics, the intervening adhesive layer will block airflow. This requires drilling.

Therefore, the adhesion process and the perforation process for the composite are required separately, and the perforation process must be performed after the adhesive has been dried or cooled, which has the disadvantage that it cannot be a continuous process and is unsuitable for mass production.

(Objective of the Invention) Therefore, the present invention provides a method for producing an air permeable composite material, which allows the composite to be bonded at the same time as drilling and is suitable for mass production.

Therefore, in the present invention, a plurality of film-like or sheet-like plastic materials, nonwoven fabrics, and cloth are stacked together in an appropriate combination including plastic materials to form a composite material, and a large number of heated needles are heated. By inserting it into the composite, a large number of micropores are made through at least the plastic material that will become the air-impermeable layer of the composite, and at the same time, the melted portion of the plastic material around each hot needle is welded to the adjacent composite forming material. This method attempts to solve the drawbacks of the conventional method by gluing the composite at a large number of hot needle insertion portions by interlocking and locking the composite.

(b) Since the composite always contains a plastic material, when a hot needle is inserted, the surrounding area melts and welds to the adjacent composite forming material, or the melted part gets entangled with the pores of the nonwoven fabric or cloth. It is fixed and glued.

(■) Also, since a hot needle is used, the plastic material can be melted and bonded to other composite forming materials.

(c) At least the plastic material of the non-breathable layer is made with micropores using a hot needle, so that it communicates with the cloth, nonwoven fabric, etc. of the breathable structure, thereby ensuring breathability.

(Example) The method of the present invention will be explained below with reference to the drawings.

First, to explain the flow hole bonding device shown in FIG. 1 used in this example, one of the pair of rolls is a hot needle roll A, and countless hot needles K are arranged at predetermined intervals on the outer peripheral surface of the roll A. It is a protruding structure. This heating needle is heated and controlled by a heating device (not shown). The other roll B is a cooling roll, and can be controlled by a cooling device (not shown) so that its surface temperature does not exceed 100°C. Note that the outer peripheral surface of the cooling roll B is surrounded by rubber.

Next, to explain the manufacturing method of this example, a polypropylene plastic film l and a plastic nonwoven fabric 2 are stacked to form a composite Sa, and this is rolled into a roll B as shown in FIG.
It is passed between rotating rolls A and B with the nonwoven fabric surface in contact with the paper.

That is, 25% above the melting temperature of polypropylene film l
The tip of a hot needle heated to 0°C is inserted into the composite Sa from the film side to penetrate the nonwoven fabric 2 (second
(see figure).

As a result, the film portion and nonwoven fabric portion surrounding the hot needle melt and weld to each other, and the composite Sa is adhered to the hot needle K. At the same time, the hot needle K is pulled out from the rotating roll A, and micropores 3 are formed in that part. Yes (see Figure 3).

In addition, since the film 1 does not come into contact with the heated outer circumferential surface of the roll A, the film 1 will not be burnt, shrink or deform, and will not cause problems to the composite.

In this example, the tip diameter of the hot needle is 0.1 mm, the base diameter is 0.5 mm, the protrusion length is 0.8 mm, and the composite S
The thickness of a is 70 microns, and the micropores 3 are transparent in the film 1.
The diameter of the pores is 0.2 mm, and the pore spacing is approximately 0.8 layers.

That is, the number of micropores 3 formed in the film 1 is more than 1,000,000 per square meter, which is extremely innumerable.

Therefore, the countless through holes 4 and original pores 2a of the nonwoven fabric 2 due to the hot needles K are communicated with the countless fine pores 3 of the film 1 to form a breathable composite material S having air permeability. Moreover, at the same time as making micro holes in the film l,
and the nonwoven fabric 2 are welded and bonded to each other around the 3 portions of the micropores, and since there are countless welded portions, the breathable composite material S is strongly bonded.

As described above, according to this example, the process of forming micropores in the composite body and the bonding process can be performed simultaneously, and since the hot needle K is inserted while the composite body Sa is moving, the process can be performed continuously.

(Structure of the Invention) Although the method of this example is constructed as described above, the method of the present invention is not limited to this. For example, the shape of the hot needle does not matter,
The size and shape of the micropores are not limited, and the composite may be appropriately combined with other composite forming materials as long as it contains a plastic material. In this case, in the case of a composite body made of multiple layers of plastic films as shown in FIG. 4, it is necessary to insert the hot needle through the composite body. For breathable materials such as non-woven fabrics and cloth, it is only necessary to insert the heating needle into the plastic film 1° as shown in Figure 5, but if the composite material is made of non-woven material, it is necessary to insert the heating needle only 1° into the plastic film. In addition, the nonwoven fabric may be made of pulp or the like in addition to plastic, and the fabric may be either natural or chemical fiber, and the hot needling process may be performed using a roll as in this example as well as an intermittent process. Alternatively, a method may be used in which the composite is pressed and a heated needle is inserted into the composite to be transferred.

Furthermore, the heating temperature of the hot needle can be set arbitrarily, as long as it can melt the plastic material and weld it to the adjacent composite material.In this case, even if the adjacent composite material is not welded by the hot needle, its through hole or It can be fixed and bonded by the transverse effect of intertwining with the micropores contacted by the needle.

In short, the present invention involves forming a composite by stacking a plurality of film-like or sheet-like plastic materials, nonwoven fabrics, and cloth as composite forming materials in an appropriate combination including plastic materials, and then applying a large number of heated hot needles. By inserting it into the composite, a large number of micropores are made through at least the plastic material that becomes the non-porous layer of the composite, and at the same time, the melted part of the plastic material around each hot needle is welded to the adjacent composite forming material. Alternatively, there is a method for producing a breathable composite material, which is characterized in that the composite is bonded at a large number of hot needle insertion portions by intertwining and locking.

(Effects of the Invention) Therefore, according to the present method invention, there are a step of making micropores through the plastic material that will become a non-porous layer by inserting a hot needle to maintain air permeability, and a step of melting the area around the hot needle of the plastic material. Since the adhesion process can be performed simultaneously in one step, the effect of rapidly manufacturing composite materials in large quantities is extremely large, and in particular, composites with three or more layers can be manufactured quickly.

Further, since the present invention does not use the gas generated by the conventional adhesive layer, there is also an advantage in terms of safe operation since no gas is generated.

[Brief explanation of drawings]

The drawings are for explaining the present invention, and FIG. 1 is a perspective view showing the process of forming microholes and bonding at the same time. Fig. 2 is an enlarged longitudinal cross-sectional view of the main part, Fig. 3 is an enlarged longitudinal cross-sectional view of the breathable composite material obtained thereby, and Fig. 4 is an enlarged longitudinal cross-sectional view of another example of the breathable composite material made of plastic film and nonwoven fabric. The plan view, FIG. 5, is an enlarged longitudinal cross-sectional view of a breathable composite material consisting of three layers of plastic film. S2 Breathable Composite Material, Sa: Composite, K: Hot Point Time 14th Year Request Ku Otsu'' Ward November 1, 1985 + Date 26 Name of Invention Method for Manufacturing Breathable Composite Material 3, Make Amendments Relationship with the case Patent applicant Address Name Daiki Slitter Co., Ltd. 4, Agent Address: 453 Ki 052 (452) 5225
Section 6, a0 of the invention increased by the amendment 7. Section 8 of "Detailed Description of the Invention" and "Brief Description of the Drawings" of the specification subject to the amendment, Contents of the amendment (contents of the amendment) 1. Specification No. Change “more than one” in the first line of page 9 to “more than one”
Correct to. 2. Correct "Figure 4" on page 11, line 12 of the same page to "Figure 5." 3. Change "Figure 5" in PIS 14 line 11 on page 11 to "Figure 4".
Correct it to "Figure". that's all

Claims (5)

[Claims] (1) A composite is formed by stacking a plurality of films or sheets of plastic material, nonwoven fabric, or cloth in an appropriate combination containing the plastic material, and a large number of heated needles are applied to the composite material. By inserting it into the composite, a large number of micropores are made through the plastic material that becomes at least the air-impermeable layer of the composite, and at the same time, the melted part of the plastic material around each hot needle is welded or entangled with the adjacent composite forming material. 1. A method for producing a breathable composite material, which comprises bonding a composite material with a large number of hot needle insertion parts by locking the composite material. (2) A large number of heating needles are provided protruding from the outer circumferential surface of the roll, and the tips of the heating needles of the rotating roll are placed on one side of the moving composite while the composite does not come into contact with the outer peripheral surface of the roll. A method for producing a breathable composite material according to claim 1, which is inserted from. (3) The method for producing a breathable composite material according to claim 1 or 2, wherein the composite is formed of a plurality of plastic films, and a hot needle is inserted into and penetrates the composite. (4) The method for producing a breathable composite material according to claim 1 or 2, wherein the composite is formed of a plastic film and a nonwoven fabric, and a hot needle is inserted into and penetrates the composite. (5) The method for producing a breathable composite material according to claim 1 or 2, wherein the composite is formed of a plastic film and a nonwoven fabric, and a hot needle is inserted so as not to penetrate the nonwoven fabric.